Construction member

ABSTRACT

A construction member is described and which includes a first portion defining a first channel; and a second portion matingly received in part, in the first channel, and which further defines a second channel which receives a first structural component therein, and wherein the first and second portions are fastened together.

TECHNICAL FIELD

The present invention relates to a construction member which finds usefulness as a header and which may be employed in the construction of doors, windows or the like, or which further can be used in place of the typical double top plate in the construction of load bearing walls or other supporting structures.

BACKGROUND OF THE INVENTION

In the construction of industrial and other commercial buildings, building codes will typically require the use of metal framing members for both interior and exterior walls. These metal studs and other construction members are well known in this same industry. Metal studs, for example, are dimensionally stable, lightweight and quite strong. These metal studs are joined together by screws or other fasteners to provide walls upon which wallboard is then attached by screws. They may further have apertures formed therein and which allow electrical and plumbing conduits to pass therethrough.

In both residential and commercial construction, a header is typically required to be secured on a framed wall and which spans a distance in the framed wall to define an opening for a door or corresponding window. The header must be exceptionally strong inasmuch as metal stud “cripples” may be attached thereto, and extend upwardly therefrom, to define the framed wall immediately above the header. In window installation, the sash of the window is coupled or otherwise fastened to the header to secure the window in the opening which is partially defined by the header. Trim or molding may then be secured to the header to make the window more aesthetically appealing. As best understood by a study of FIGS. 1 and 2 which are marked as prior art, various attempts have been made to arrange the available prior art metal construction members in assorted arrangements to achieve the strength necessary so that the resulting assembly operates as a header. While the prior art assemblies which are shown in FIGS. 1 and 2 work with some degree of success, both arrangements have readily identifiable shortcomings which have detracted from their respective usefulness. For example, the prior art examples shown in FIGS. 1 and 2 include a multiplicity of components including various fasteners and brackets of assorted shapes and sizes in order for the resulting header to be installed correctly. Yet further, it should be apparent that the time required to assemble each of the prior art headers is considerable. Further, in view of the components which make up such an assembly, the cost associated with each of these structures is relatively expensive.

Therefore, it has long been known that it would be desirable to have a construction member which could be employed in the fabrication of a framed wall, and which would operate as a header and which would achieve many of the benefits to be derived from such prior art construction members, but which would avoid the detriments and other shortcomings associated with the prior art practices.

SUMMARY OF THE INVENTION

A first aspect of the present invention relates to a construction member which includes a first portion defining a first channel; and a second portion matingly received in part in the first channel, and which further defines a second channel which receives a first structural component therein, and wherein the first and second portions are fastened together.

Another aspect of the present invention relates to a construction member which includes a receiver mounted on a structural component; a first portion having a main body with a width dimension, and which defines a first channel having a width dimension which is less than about 80% of the width dimension of the main body, and wherein the first portion is received in mating relation relative to the receiver; and a second portion which has a main body which is received in part in the first channel, and which is affixed to the first portion, and wherein the second portion defines a second channel which receives another structural component.

Another aspect of the present invention relates to a construction member which includes a first portion having a main body which is defined by a plurality of courses, and wherein the main body includes a first course, a second course joined to the first course, and disposed in substantially perpendicular relation thereto, a third course joined to the second course and which is disposed in angulated relation relative thereto, a fourth course joined to the third course and which is disposed in predetermined, spaced, substantially parallel relation relative to the second course, and a fifth course joined to the fourth course and which is substantially perpendicular relative thereto, and wherein a first channel is defined therebetween the first and fifth courses; and a second portion having a main body which has a plurality of courses, and wherein the main body has a first course which is joined to a second course, and wherein the second course is disposed in substantially perpendicular relation relative thereto, and which is further disposed in juxtaposed rested relation thereagainst the first course of the first portion, a third course which is joined to the second course and which is substantially perpendicular relative thereto, and which is disposed in substantially parallel spaced relation relative to the second course of the first portion; a fourth course joined to the third course, and which is disposed in juxtaposed resting relation thereagainst the third course of the first portion, a fifth course joined to the fourth course and which is disposed in substantially parallel spaced relation relative to the fourth course of the first portion, and is further in substantially parallel spaced relation relative to the third course of the second portion, a sixth course joined to the fifth course, and which is disposed in juxtaposed resting relation thereagainst the fifth course of the first portion, and a seventh course which is joined to the sixth course and which is disposed in substantially perpendicular relation relative thereto and further is disposed in substantially parallel, spaced relation relative to the first course of the second portion, and wherein the first and seventh courses define, in part, a second channel and which is operable to receive a structural component therein, and wherein the third, fourth and fifth courses of the second portion define a male member which is matingly received in the first channel, and wherein the first and second portions are fastened together.

These and other aspects of the present invention will be discussed in greater detail hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention are described below with reference to the following accompanying drawings.

FIG. 1 is a perspective, fragmentary view of a prior art header arrangement.

FIG. 2 is a perspective, fragmentary view of a second prior art header arrangement.

FIG. 3 is a perspective, exploded view of the construction member of the present invention.

FIG. 4 is a perspective, fragmentary view of the assembled construction member of the present invention.

FIG. 5 is a side elevational view of the construction member of the present invention shown in an installed arrangement as a header for a window.

FIG. 6 is a fragmentary, perspective view of the construction member of the present invention shown in an installed arrangement in place of a double top plate to support adjoining roof trusses.

FIG. 7 is a fragmentary, transverse, vertical sectional view of the present invention and which is taken along line 7-7 of FIG. 6.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

This disclosure of the invention is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (Article 1, Section 8).

Referring now to FIG. 1, a first form of a prior art header arrangement which may be fabricated to span the distance in a framed wall is shown in this fragmentary view. As seen therein, the first form of the prior art header 10 is affixed to a door jamb 11 of traditional design. The first form 10 of the prior art header is fabricated from a plurality of C-shaped metal channel members designated by the numeral 12 and which are oriented in a substantially horizontal relationship and are disposed in affixed substantially parallel relation one relative to the others. Still further and as seen in FIG. 1, a substantially I-shaped load bearing member 13 is received between a pair of adjacent C-shaped channels to provide rigidity to the header 10. This I-shaped load bearing member is typically formed by joining the C-shaped members together. Yet further, and at predetermined space distances along the header, vertically oriented C-shaped channels 14 are utilized to span the distance between adjoining horizontally oriented C-shaped channels in order to provide yet further strength to the overall prior art header arrangement 10. A second form of a prior art arrangement is shown in FIG. 2. As seen therein, the second form of the prior art header 20 is affixed to a vertically oriented construction member or door jamb 21. It is similarly fabricated from a plurality of C-shaped channel members 22 which are fastened together by screws, and less commonly rivets, to form a resulting hollow beam 23. Yet further, the hollow beam 23 rests in contact with an L-shaped bracket 24 which is attached to the door jamb 21 by a plurality of screws and less commonly rivets. As seen in FIG. 2, at least one cripple 25 extends upwardly from the hollow beam 23 in order to define the wall thereabove the prior art header 20. The cripples 25 and jambs 21 are usually metal studs with stiffening lips on the flanges (not shown).

Referring now to FIG. 5, the construction member of the present invention is generally indicated by the numeral 30. As seen therein, the construction member 30 may be employed as a header for a window or a door or further and as seen in FIGS. 6 and 7 may be used in place of a double top plate in the construction of a wall. These aspects of the invention will be discussed in greater detail below. Referring to FIG. 5, a traditional framed wall 31 is generally shown. The framed wall is affixed on a foundation or supporting surface 32. The wall 31 includes a bottom plate 33, and a top plate 34 which is spaced in predetermined substantially parallel relation relative thereto. Affixed to the bottom plate and extending in substantially vertically oriented relation relative thereto are a plurality of vertically oriented supporting members or studs 35. Typically the studs are typically positioned on 16 and/or 24 inch centers (which are the most common). In the framed wall 31 as shown in FIG. 5, a window jamb 36 is provided. Still further, the construction member 30 spans between adjacent window jambs 36 and further a plurality of first structural components or cripples 37 extend upwardly above the construction member 30 to define that portion of the wall 31 above and adjacent to the window opening 38.

As best seen by reference to FIGS. 3 and 5, the construction member of the present invention includes a receiver 40 which is affixed by a suitable fastener such as a screw, and less commonly a rivet, or the like on a second structural component here shown in FIG. 5 as the window jamb 36. The receiver 40 has a main body 41 which is affixed directly to the adjacent second structural component or window jamb 40 and further has a plurality of sidewalls or tabs 42 which extend generally normally, outwardly therefrom in order to define a channel 43. The channel 43 has a predetermined width dimension which is operable to receive the first portion of the construction member which is generally indicated by the numeral 50 and is best understood by a study of FIG. 3. As seen in that view, the first portion 50 of the construction member 30 has a main body 51 which has opposite first and second ends 52 and 53, respectively. It should be understood, at least one end of the main body is received in one of the receivers 40 and is affixed thereto by means of a rivet or screwthreadable fastener such that force applied to the construction member 30 is transmitted to the receiver 40 in screw shear. The main body 51 is further defined by a pair of spaced apart legs 54. Each of the legs 54 have a proximal end 55 and an opposite distal end 56. The distal end of each of the respective legs includes a flange portion 60 which is angularly disposed relative to the respective legs 54. Each flange portion 60 has a width dimension which is equal to or greater than about 10% of the width dimension of the first portion. The width dimension of the first portion 50 is measured between the spaced apart legs 54. As seen in FIG. 3 and following, the first portion 50 is defined by a plurality of courses. In this regard, the plurality of courses includes a first course 61, and a second course 62 which is joined to the first course 61, and disposed in substantially perpendicular relation thereto. A third course 63 (FIG. 4) is joined to the second course 62 and which is disposed in angulated relation relative thereto. A fourth course 64 is joined to the third course 63 and which is disposed in predetermined, spaced, substantially parallel relation relative to the second course 62. A fifth course 65 is provided and joined to the fourth course 64 and which is substantially perpendicular relative thereto. As seen in FIG. 3 and following, a first channel 70 is defined therebetween the first and fifth courses 61 and 65, respectively. As seen in FIG. 3 for example, the first channel which is defined between the first and fifth courses 61 and 65 has not only a width dimension but a depth dimension which is measured between the respective first and fifth courses, and the third course. As best understood by a study of FIG. 4, the width dimension of the receiver 40 is greater than the width dimension of the first portion 50 such that the first portion 50 can otherwise be nested or received within the receiver 40 as illustrated. The first portion 50 has an interior facing surface 71 and an opposite exterior facing surface 72.

Referring now to FIG. 3 and following, the construction member 30 of the present invention includes a second portion which is generally indicated by the numeral 80 and which is matingly received, at least in part, in the channel 70 which is defined by the first portion 50. In this regard the second portion has a main body 81 which defines a male member 82 which is received in the channel 70, and which is defined by the first portion. This main body 81 is further defined by a pair of opposite shoulder regions 83. As seen in the drawings, the respective shoulder regions 83 are positioned on the opposite sides of the male member 82. When assembled, these same shoulder regions are positioned in juxtaposed rested relation thereagainst the respective flange portions 60 (FIG. 4). The respective shoulder regions 83 each have a width dimension which is equal to or greater than about 20% of the width dimension of the adjoining flange portions 60. As seen in FIG. 4, the male member 82, which is received in mating relation in the first channel 70, has a distal end 84 which defines a surface which will be described below, and which lies in juxtaposed engagement thereagainst the first portion 50. The distal end 84 of the male portion has a predetermined width dimension which is less than about 80% of the width dimension of the first portion 50. Yet further, the width dimension of the male member 82 is less than about the width dimension of the first channel 70 as measured between the first and fifth courses 61 and 65, respectively. In addition to the foregoing, the length dimension of the male member 82 is less than the depth dimension of the first channel 70 as measured between the first and fifth courses 61 and 65 and the third course 63.

The second portion 80 defines a second channel 90 which is operable to receive a structural component as will be described below. As illustrated, the second channel 90 has a width dimension which is greater than about the width dimension of the first portion. As should be understood, in certain forms of the invention, the width dimension of the second channel could be less than the width dimension of the first portion without departing from the nature of the present invention. The main body 81 is defined by a plurality of courses. In this regard, the main body has a first course 91 which is joined to a second course 92. As seen in the drawings, the second course 92 is disposed in substantially perpendicular relation relative thereto, and is further disposed in juxtaposed rested relation thereagainst the first course 61 of the first portion 50. A third course 93 is provided and which is joined to the second course 92, and which is substantially perpendicular relative thereto. The third course is disposed in substantially parallel spaced relation relative to the second course 62 of the first portion 50. A fourth course 94 is provided and is joined to the third course 93, and which is disposed in juxtaposed resting relation thereagainst the third course 63 of the first portion. The fourth course 94 comprises the distal end 84 of the male member 82. As earlier discussed, the fourth course 94 defines the width dimension for the male member 82, and which is less than the width dimension of the first channel 70. A fifth course 95 is provided and is joined to the fourth course 94, and which is further disposed in substantially parallel, spaced relation relative to the fourth course 64 of the first portion 50. The fifth course 95 is further in substantially parallel spaced relation relative to the third course 93 of the second portion 80. A sixth course 96 is provided and is joined to the fifth course 95, and which is disposed in juxtaposed resting relation thereagainst the fifth course 65 of the first portion 50. A seventh course 97 is provided and which is joined to the sixth course 96 and which is disposed in substantially perpendicular relation relative thereto, and further is disposed in substantially parallel, spaced relation relative to the first course 91 of the second portion 80. As seen in the drawings, the first and seventh courses 91 and 97, respectively define, in part, the second channel 90 and which is operable to receive a structural component as will be described below. Still further, the third, fourth and fifth courses 93, 94 and 95 of the second portion 80 define the male member 82 which is matingly received in the first channel 70. As seen more clearly by reference to FIG. 7 which shows the present invention employed in place of a double top plate. The respective first and second portions 50 and 80 are held to together by a plurality of fasteners 98 thereby forming an integral body.

As earlier discussed, the construction member 30 of the present invention may be employed as a header for a window or door as seen in FIG. 5 or further can be employed in the place of a double top plate in the construction of a wall as seen in FIGS. 6 and 7, respectively. Typically in the construction of a wall as seen, for example in FIG. 5, a top plate 34 is typically provided. In most construction, such as frame construction for houses and the like, the top plate 34 comprises two 2×6 members which are nailed or otherwise secured together and upon which the roof trusses rest and are otherwise secured.

Referring now to FIG. 6, the construction member 30 of the present invention can replace the double top plate typically used in such construction and can support a plurality of roof trusses generally indicated by the numeral 100.

As seen in FIG. 7, the construction member 30 and more specifically the channel 90 is operable to receive the ends of several studs 35 or cripples 37 therein. These construction members are secured in channel 90 by means of a suitable fastener. The first and second portions 50 and 80 respectively are joined together by a plurality of fasteners 98. It will be seen by a study of FIG. 7 that the respective roof trusses rest thereagainst the exterior facing surface 72 of the third course 63 which is defined by the first portion 50. The respective roof trusses can be secured to the construction member 30 in traditional ways by fasteners such as screws and the like and which are received through a bracket 101 which is secured to the adjoining roof truss. In the alternative, the adjoining roof truss 100 may be secured to construction member 30 by means of fasteners, such as a screw, which extends through the construction member 30 and into the roof truss. This would eliminate the need for the bracket 101.

OPERATION

The operation of the described embodiment of the present invention is believed to be readily apparent and is briefly summarized at this point.

A construction member 30 of the present invention is best understood by a study of FIG. 3 and following. The construction member 30 includes a first portion 50 defining a first channel 70; and a second portion 80 is matingly received, in part, in the first channel 70, and which further defines a second channel 90 which receives a first structural component 31 or 37 therein, and wherein the first and second portions are fastened together. In addition to the foregoing, the construction member of the present invention further includes a receiver 40 which is mounted on an adjacent second structural component such as a door jamb, window jamb or the like such as indicated by the numeral 36 in FIG. 5 and wherein the first portion 50 is affixed to the receiver 40. As seen in the drawings, the second portion 80 has a main body 81 which defines in part, a male member 82, and wherein the male member is received in the first channel 70 and rests, in part, in juxtaposed relation thereagainst the first portion 50. As earlier discussed, the first portion 50 is defined, in part, by a pair of spaced apart legs 54. Each leg has a proximal and a distal end 55 and 56, respectively. The distal end 56 of each leg 54 rests in juxtaposed relation thereagainst the second portion 80. As seen in the drawings, the male member and/or the distal end of the respective legs are fastened together by using a suitable fastener 98 to the second portion 80. In the arrangement as shown, the male member 82 has a length and width dimension, and the first channel 70 has a width and depth dimension, and wherein the width dimension of the male member is less than the width dimension of the first channel 70, and the length dimension of the male member is greater than the depth dimension of the first channel 70. In the arrangement as shown, the spaced apart legs 54 of the first portion 50 define the width dimension of the first portion 50, and wherein the width dimension of the male member 82 is about 20% to about 80% of the width dimension of the first portion. In the arrangement as shown, the width dimension of the first channel 70 is typically less than about 80% of the width dimension of the first portion 70.

Therefore it will be seen that the construction member of the present invention provides a convenient means whereby a header can be readily formed in a fashion not possible heretofore. Still further, the construction member of the present invention also provides further advantages inasmuch as the same construction member can be utilized in place of a double top plate in the construction of a framed wall or the like.

In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents. 

1. A construction member comprising: a first portion defining a first channel; and a second portion matingly received, in part, in the first channel, and which further defines a second channel which receives a first structural component therein, and wherein the first and second portions are fastened together.
 2. A construction member as claimed in claim 1, and wherein the construction member is employed as a header for a window or a door, or further can be employed in place of a double top plate in the construction of a wall.
 3. A construction member as claimed in claim 1, and further comprising a receiver which is mounted on an adjacent second structural component, and wherein the first portion is affixed to the receiver.
 4. A construction member as claimed in claim 3, and wherein the second portion has a main body which defines at least in part, a male member, and wherein the male member is received in the first channel and rests, in part, in juxtaposed relation relative to the first portion.
 5. A construction member as claimed in claim 4, and wherein the first portion is defined, in part, by a pair of spaced apart legs and wherein each leg has a proximal and a distal end, and wherein the distal end of each leg rests in juxtaposed relation relative to the second portion.
 6. A construction member as claimed in claim 5, and wherein the male member and/or the distal end of the respective legs are fastened to the second portion.
 7. A construction member as claimed in claim 6, and wherein the male member has a length and width dimension, and the first channel has a width and depth dimension, and wherein the width dimension of the male member is less than the width dimension of the first channel, and the length dimension of the male member is greater than the depth dimension of the first channel.
 8. A construction member as claimed in claim 7, and wherein the spaced apart legs of the first portion define the width dimension of the first portion, and wherein the width dimension of the male member is about 20% to about 80% of the width dimension of the first portion.
 9. A construction member as claimed in claim 8, and wherein the second channel has a width dimension which is greater than the width dimension of the first portion.
 10. A construction member as claimed in claim 8, and wherein the second channel has a width dimension which is less than the width dimension of the first portion.
 11. A construction member as claimed in claim 8, and wherein the width dimension of the first channel is less than about 80% of the width dimension of the first portion.
 12. A construction member comprising: a receiver mounted on a structural component; a first portion having a main body with a width dimension, and which defines a first channel having a width dimension which is less than about 80% of the width dimension of the main body, and wherein the first portion is received in mating relation relative to the receiver; and a second portion which has a main body which is received, in part, in the first channel, and which is affixed to the first portion, and wherein the second portion defines a second channel which receives another structural component.
 13. A construction member as claimed in claim 12, and wherein the second portion defines a male member which is received in mating relation in the first channel, and wherein the male member has a distal end which defines a surface which lies in juxtaposed engagement thereagainst the first portion, and wherein the distal end of the male portion defining the surface has a width dimension, and wherein the first portion has a width dimension, and wherein the width dimension of the of the surface which is defined by the distal end of the male member is less than about 80% of the width dimension of the first portion.
 14. A construction member as claimed in claim 13, and wherein the main body of the first portion further has a pair of spaced legs each having a distal end, and wherein the distal end of each leg further includes a flange portion which is angularly disposed relative to the respective legs, and wherein each flange portion has a width dimension, and wherein the width dimension of the flange portion is equal to or greater than about 10% of the width dimension of the first portion, and wherein the respective flange portions lie in juxtaposed relation thereagainst the second portion.
 15. A construction member as claimed in claim 14, and wherein the main body of the second portion defines respective shoulder regions on the opposite sides of the male member, and wherein the respective flange portions are juxtaposed thereagainst the respective shoulder regions, and wherein the respective shoulder regions each have a width dimension which is equal to or greater than about 20% of the width dimension of the adjoining flange portions.
 16. A construction member as claimed in claim 15, and wherein the second channel has a width dimension which is greater than about the width dimension of the first portion.
 17. A construction member as claimed in claim 15, and wherein the second channel has a width dimension which is equal to or less than the width dimension of the first portion.
 18. A construction member as claimed in claim 17, and wherein the receiver includes sidewalls which defines a channel having a width dimension, and wherein the width dimension of the receiver is greater than the width dimension of the first portion.
 19. A construction member comprising: a first portion having a main body which is defined by a plurality of courses, and wherein the main body includes a first course, a second course joined to the first course, and disposed in substantially perpendicular relation thereto, a third course joined to the second course and which is disposed- in angulated relation relative thereto, a fourth course joined to the third course and which is disposed in predetermined, spaced, substantially parallel relation relative to the second course, and a fifth course joined to the fourth course and which is substantially perpendicular relative thereto, and wherein a first channel is defined therebetween the first and fifth courses; and a second portion having a main body which has a plurality of courses, and wherein the main body has a first course which is joined to a second course, and wherein the second course is disposed in substantially perpendicular relation relative thereto, and which is further disposed in juxtaposed rested relation thereagainst the first course of the first portion, a third course which is joined to the second course and which is substantially perpendicular relative thereto, and which is disposed in substantially parallel spaced relation relative to the second course of the first portion; a fourth course joined to the third course, and which is disposed in juxtaposed resting relation thereagainst the third course of the first portion, a fifth course joined to the fourth course and which is disposed in substantially parallel spaced relation relative to the fourth course of the first portion, and is further in substantially parallel spaced relation relative to the third course of the second portion, a sixth course joined to the fifth course, and which is disposed in juxtaposed resting relation thereagainst the fifth course of the first portion, and a seventh course which is joined to the sixth course and which is disposed in substantially perpendicular relation relative thereto and further is disposed in substantially parallel, spaced relation relative to the first course of the second portion, and wherein the first and seventh courses define, in part, a second channel and which is operable to receive a structural component therein, and wherein the third, fourth and fifth courses of the second portion define a male member which is matingly received in the first channel, and wherein the first and second portions are fastened together.
 20. A construction member as claimed in claim 19, and wherein the first portion has opposite ends, and a width dimension, and wherein the construction member further comprises a receiver which has sidewalls and which defines a channel, and wherein at least one end of the first portion is received in the channel, and wherein the first portion is screwthreadably fastened to the receiver, and wherein force applied to the construction member is transmitted to the receiver in screw shear.
 21. A construction member as claimed in claim 20, and wherein the second channel has a width dimension which is greater than the width dimension of the first portion.
 22. A construction member as claimed in claim 20, and wherein the second channel has a width dimension which is less than the width dimension of the first portion.
 23. A construction member as claimed in claim 20, and wherein third course of the first portion is substantially planar, and disposed at a substantially perpendicular orientation relative to the second and fourth courses of the first portion.
 24. A construction member as claimed in claim 20, and wherein the third course of the first portion is non-planar. 